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Macro Meso and Microturning

Microturning is a micromachining process used to machine very small parts with diameters less than 1 mm. It differs from macroturning in several key ways. The size of features being machined is much smaller, requiring precision of only a few microns. The cutting mechanism changes from bulk material removal through shearing to removal across grain boundaries due to the chip cross-section being smaller than the grain size. Workpieces also lack rigidity at the microscale and deform more easily during machining. Tolerances achievable are less precise when scaled to the size of the micro-components. This chapter provides an overview of the microturning process.

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137 views1 page

Macro Meso and Microturning

Microturning is a micromachining process used to machine very small parts with diameters less than 1 mm. It differs from macroturning in several key ways. The size of features being machined is much smaller, requiring precision of only a few microns. The cutting mechanism changes from bulk material removal through shearing to removal across grain boundaries due to the chip cross-section being smaller than the grain size. Workpieces also lack rigidity at the microscale and deform more easily during machining. Tolerances achievable are less precise when scaled to the size of the micro-components. This chapter provides an overview of the microturning process.

Uploaded by

pkjhan1353
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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56 Micromanufacturing Processes

higher quality and improved performance at lower cost. Micromanufacturing processes


such as micromachining, microforming, microjoining, and microassembly play a vital
role in the miniaturization of components and systems. Of the many micromachining
processes, microturning is one of the most basic technologies for the production of min-
iaturized parts and components. Working in the area of miniaturization in general and
microturning in particular needs a thorough understanding of the microturning process,
including the basic differences between microturning and macroturning processes, criti-
cal requirements of the microturning machines, underlying mechanisms of the material
removal process, various factors that affect the accuracy of the component, tools for micro-
turning, and the effects of various machining parameters on the process performance.
This chapter provides an overview of microturning to researchers, teachers, and students.

3.2 Macro-, Meso-, and Microturning


Turning of small parts is not new, but challenges arise when the size of features reduce
to tens or hundreds of microns, and the precision requirements of the miniaturized parts
become less than a few microns. Even though microturning is a miniaturized version of
macro/mesoturning, there exist a few fundamental differences between them. Some
of them are as follows:

r The main feature that distinguishes macro/mesoturning from microturning is the


size attribute of the component, specifically the diameter being machined. Macro/
mesoturning is applicable to component diameters of ≥ 1 mm, whereas microturn-
ing is applicable when the diameter of the component is < 1 mm. Although there
are different definitions for the upper limit of the diameter in the case of micro-
turning, machining of < 1 mm diameter is generally accepted by many.
r The second feature that distinguishes microturning from macro/mesoturning is
the cutting mechanism. Cutting in macro/mesoturning is the shearing of bulk mate-
rial along the average shear plane with high defect density; machining parameters
lead to larger chip cross section encompassing a large number of grains, whereas
in microturning the material is removed with very small chip cross section,
generally, less than the average grain size. Under this condition, the material is
not removed by shear along the grain boundaries but across the grains. The size
effect becomes a dominant phenomenon, and it tremendously increases the spe-
cific cutting energy.
r The third factor that distinguishes them is the lack of rigidity of the component
in microturning. While machining, the workpiece deflects and causes a large
variation in shape and size. The magnitude of the cutting force in microturning
deflects the component not only along the direction of the thrust force but also in
the tangential direction, thus changing the center height of the tool and leading
to a damaged workpiece. Hence, control of the reaction forces in microturning is
a major issue.
r The fourth factor is the attainable tolerance on the component. With microturn-
ing, a ratio of “tolerance to the size of the component” similar to that achieved
in macro/mesoturning cannot be attained. For example, when the tolerance on

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